Table of Contents Table of Contents Introduction and Safety .......................................................................................................... 4 Introduction ............................................................................................................................. 4 Safety ...................................................................................................................................... 4 Safety terminology and symbols ..........................
Table of Contents Couple the pump and driver .................................................................................................. Coupling guard assembly ................................................................................................... Bearing lubrication .............................................................................................................. Shaft sealing with a mechanical seal ...........................................................................
Table of Contents Assembly troubleshooting ................................................................................................... 103 Parts Listings and Cross-Sectionals ................................................................................. 104 Parts list .............................................................................................................................. 104 Local ITT Contacts .................................................................................
Introduction and Safety Introduction and Safety Introduction Purpose of this manual The purpose of this manual is to provide necessary information for: • Installation • Operation • Maintenance CAUTION: Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty. NOTICE: Save this manual for future reference, and keep it readily available at the location of the unit.
Introduction and Safety Safety terminology and symbols About safety messages It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product.
Introduction and Safety • Clean up all spills in accordance with safety and environmental procedures. • Report all environmental emissions to the appropriate authorities. WARNING: Do NOT send the product to the ITT manufacturer if it has been contaminated by any nuclear radiation. Inform ITT so that accurate actions can take place. Electrical installation For electrical installation recycling requirements, consult your local electric utility.
Introduction and Safety • • • • • • • • Make sure that the product cannot roll or fall over and injure people or damage property. Make sure that the lifting equipment is in good condition. Use a lifting harness, a safety line, and a breathing device as required. Make sure that the product is thoroughly clean. Make sure that there are no poisonous gases within the work area. Make sure that you have quick access to a first-aid kit. Disconnect and lock out power before servicing.
Introduction and Safety If there are any questions regarding these requirements, the intended use, or if the equipment requires modification, contact an ITT representative before you proceed. Personnel requirements ITT disclaims all responsibility for work done by untrained and unauthorized personnel. These are the personnel requirements for Ex-approved products in potentially explosive atmospheres: • All work on the product must be carried out by certified electricians and ITT-authorized mechanics.
Introduction and Safety • • • • • • The faults are reported to an ITT representative within the warranty period. The product is used only under the conditions described in this manual. The monitoring equipment incorporated in the product is correctly connected and in use. All service and repair work is done by ITT-authorized personnel. Genuine ITT parts are used. Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved products.
Transportation and Storage Transportation and Storage Inspect the delivery Inspect the package 1. Inspect the package for damaged or missing items upon delivery. 2. Note any damaged or missing items on the receipt and freight bill. 3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the distributor. Inspect the unit 1. Remove packing materials from the product.
Transportation and Storage Examples Figure 1: Example of a proper lifting method Figure 2: Example of a proper lifting method Model 3700, API Type OH2 / ISO 13709 1st and 2nd Ed. / API 610 8/9/10/11th Ed.
Transportation and Storage Figure 3: Example of a proper lifting method Figure 4: Example of offset overhead motor mount pump proper lifting method Storage guidelines Pump storage requirements Storage requirements depend on the amount of time that you store the unit. The normal packaging is designed only to protect the unit during shipping. Length of time in storage Upon receipt/short-term (less than six months) 12 Storage requirements • Store in a covered and dry location.
Transportation and Storage Length of time in storage Long-term (more than six months) Storage requirements • Store in a covered and dry location. • Store the unit free from heat, dirt, and vibrations. • Rotate the shaft by hand several times at least every three months. Treat bearing and machined surfaces so that they are well preserved. Refer to drive unit and coupling manufacturers for their long-term storage procedures.
Product Description Product Description General description 3700 Product description The Model 3700 is a high-pressure, high-temperature centrifugal pump that meets the requirements of API Standard 610 10th Edition (ISO 13709). Figure 5: 3700 pump Casing The casing is a centerline-mounted design. The gasket is fully confined. The standard flanges are ANSI Class 300 raised-face serrated.
Product Description Seal-chamber cover The seal-chamber cover meets API 682 3rd Edition dimensions for improved performance of mechanical seals. Power end The power end has the following characteristics: • Standard ring oil-lubricated bearings • Labyrinth seals on the power end • Optional pure and purge oil mist lubrication (some machining is required to convert from ring oil lubrication to oil mist) Shaft The standard shaft is machined and ground to comply with API 610 11th Edition (ISO 13709) criteria.
Product Description Nameplate types Nameplate Pump casing ATEX IECEx Description Provides information about the hydraulic characteristics of the pump. The formula for the pump size is: Discharge x Suction - Nominal Maximum Impeller Diameter in inches. (Example: 2x3-8) If applicable, your pump unit might have an ATEX nameplate affixed to the pump, the baseplate, or the discharge head. The nameplate provides information about the ATEX specifications of this pump.
Product Description Nameplate on the pump casing using metric units Nameplate field MODEL SIZE FLOW HEAD RPM HYDRO PRESS MAX. DES. WORKING PRESS S/N CONT./ITEM NO. IMP. DIA. MAX. DIA. STD. DIM.
Product Description Table 5: Temperature class definitions Code Maximum permissible surface temperature in °F (°C) T1 842 (450) T2 572 (300) T3 392 (200) T4 275 (135) T5 212 (100) T6 185 (85) Minimum permissible surface temperature in °F (°C) 700 (372) 530 (277) 350 (177) 235 (113) Option not available Option not available NOTICE: Make sure that the code classifications on the pump are compatible with the specific environment in which you plan to install the equipment.
Installation Installation Preinstallation Precautions WARNING: • When installing in a potentially explosive environment, make sure that the motor is properly certified. • You must earth (ground) all electrical equipment. This applies to the pump equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to verify that it is connected correctly. • Electrical Connections must be made by certified electricians in compliance with all international, national, state, and local rules.
Installation • Provide a flat, substantial concrete foundation in order to prevent strain and distortion when you tighten the foundation bolts. • Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow movement for the final bolt adjustment. Sleeve-type bolts 1. 2. 3. 4. 5. 6. Baseplate Shims or wedges Foundation Sleeve Dam Bolt 1. 2. 3. 4. 5.
Installation NOTICE: You may need to sandblast the surfaces of a baseplate that come in contact with grout, and then coat those surfaces with a primer that is grout-compatible. Make sure to remove all equipment before sandblasting. 3. Make sure that all machined surfaces are free from burrs, rust, paint, or any other type of contamination. If necessary, use a honing stone to remove burrs. Prepare the foundation for mounting 1. Chip the top of the foundation to a minimum of 1.0 in. (25.
Installation d) Make sure that the center jackscrews do not touch the foundation surface yet. 1. 2. 3. 4. Jackscrew Baseplate Foundation Plate 3. Level the driver mounting pads: NOTICE: Remove all dirt from the mounting pads in order to make sure that you achieve the correct leveling. Failure to do so can result in equipment damage or decreased performance. a) Put one machinist's level lengthwise on one of the two pads. b) Put the other machinist's level across the ends of the two pads.
Installation Pump-to-driver alignment Precautions WARNING: • Follow shaft alignment procedures in order to prevent catastrophic failure of drive components or unintended contact of rotating parts. Follow the coupling installation and operation procedures from the coupling manufacturer. • Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury.
Installation Permitted indicator values for alignment checks NOTICE: The specified permitted reading values are valid only at operating temperature. For cold settings, other values are permitted. You must use the correct tolerances. Failure to do so can result in misalignment and reduced pump reliability. IMPORTANT • For electric motors, the motor shaft initial (cold) parallel vertical alignment setting should be 0.002 to 0.004 in. (0.05 to 0.10 mm) lower than the pump shaft.
Installation 2. Rotate the pump coupling half (X) in order to check that the indicators are in contact with the driver coupling half (Y) but do not bottom out. 3. Adjust the indicators if necessary. Pump-to-driver alignment instructions Perform angular alignment for a vertical correction 1. Set the angular alignment indicator to zero at the top-center position (12 o’clock) of the driver coupling half (Y). 2. Rotate the indicator to the bottom-center position (6 o’clock). 3. Record the indicator reading.
Installation Figure 7: Example of incorrect horizontal alignment (top view) 4. Repeat the previous steps until the permitted reading value is achieved. Perform parallel alignment for a vertical correction Refer to the alignment table in "Permitted indicator values for alignment checks" (see Table of Contents for location of table) for the proper cold alignment value based on the motor temperature rise and the pump operating temperature.
Installation When the reading value is... Negative Positive Then... The driver coupling half (Y) is to the left of the pump coupling half (X). The driver coupling half (Y) is to the right of the pump coupling half (X). 4. Slide the driver carefully in the appropriate direction. NOTICE:Make sure to slide the driver evenly. Failure to do so can negatively affect horizontal angular correction. Figure 9: Example of incorrect horizontal alignment (top view) 5.
Installation 2. Build a dam around the foundation. 3. Thoroughly wet the foundation that will come into contact with the grout. 4. Pour grout through the grout hole into the baseplate up to the level of the dam. When you pour the grout, remove air bubbles from it by using one of these methods: • Puddle with a vibrator. • Pump the grout into place. 5. Allow the grout to set. 1. 2. 3. 4. 5. 6. 7. Baseplate Shims or wedges Grout Foundation Sleeve Dam Bolt 6.
Installation Piping checklists General piping checklist Precautions CAUTION: • Never draw piping into place by using force at the flanged connections of the pump. This can impose dangerous strains on the unit and cause misalignment between the pump and driver. Pipe strain adversely affects the operation of the pump, which results in physical injury and damage to the equipment. • Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the suction side.
Installation Example: Installation for expansion Correct 1. Incorrect Expansion loop/joint Suction-piping checklist Performance curve reference Net positive suction head available (NPSHA) must always exceed NPSH required (NPSHR) as shown on the published performance curve of the pump. Suction-piping checks Check Check that the distance between the inlet flange of the pump and the closest elbow is at least five pipe diameters. Check that elbows in general do not have sharp bends.
Installation Liquid source below the pump Check Explanation/comment Make sure that the suction piping This helps to prevent the occuris free from air pockets. rence of air and cavitation in the pump inlet. Check that the suction piping — slopes upwards from the liquid source to the pump inlet. If the pump is not self-priming, Use a foot valve with a diameter check that a device for priming the that is at least equivalent to the pump is installed. diameter of the suction piping.
Installation Example: Suction piping equipment Correct 1. 2. 3. 4. 5. Incorrect Suction pipe sloping upwards from liquid source 1. Long-radius elbow Strainer Foot valve Eccentric reducer with a level top Air pocket, because the eccentric reducer is not used and because the suction piping does not slope gradually upward from the liquid source Discharge piping checklist Checklist Check Check that an isolation valve is installed in the discharge line.
Installation Example: Discharge piping equipment Correct Incorrect 1. 2. 3. 4. 1. 2. Bypass line Shut-off valve Check valve Discharge isolation valve Check valve (incorrect position) The isolation valve should not be positioned between the check valve and the pump. Bypass-piping considerations When to use a bypass line Provide a bypass line for systems that require operation at reduced flows for prolonged periods.
Installation When to install You may need to install auxiliary piping for bearing cooling, seal-chamber cover cooling, mechanical seal flush, or other special features supplied with the pump. Consult the pump data sheet for specific auxiliary piping recommendations. Checklist Check Check that the minimum flow for each component is 1 gpm (4 lpm). If the bearing and seal chamber cover cooling are provided, then the auxiliary piping must flow at 2 gpm (8 lpm).
Commissioning, Startup, Operation, and Shutdown Commissioning, Startup, Operation, and Shutdown Preparation for startup DANGER: Avoid death or serious injury. Explosion and/or seizure of pump can cause fire and/or burns. Never operate pump past the pressure and temperature limits shown on the nameplate on the pump. WARNING: • Failure to follow these precautions before you start the unit will lead to serious personal injury and equipment failure.
Commissioning, Startup, Operation, and Shutdown You must follow these precautions before you start the pump: • Flush and clean the system thoroughly to remove dirt or debris in the pipe system in order to prevent premature failure at initial startup. • Bring variable-speed drivers to the rated speed as quickly as possible. • Run a new or rebuilt pump at a speed that provides enough flow to flush and cool the close-running surfaces of the stuffing-box bushing.
Commissioning, Startup, Operation, and Shutdown Check the rotation - Frame Mounted WARNING: • Operating the pump in reverse rotation can result in the contact of metal parts, heat generation, and breach of containment. • Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury. 1. Lock out power to the driver. 2.
Commissioning, Startup, Operation, and Shutdown 1. 2. 3. 4. 5. 6. End plate, drive end End plate, pump end Guard half, 2 required 3/8-16 nut, 3 required 3/8 in. washer 3/8-16 x 2 in. hex head bolt, 3 required Install the coupling guard 1. Is the end plate (pump end) already installed? • If yes: Make any necessary coupling adjustments and then proceed to step 2. • If no: Complete these steps: a) Remove the spacer portion of the coupling.
Commissioning, Startup, Operation, and Shutdown Complete any coupling adjustments before you proceed with the coupling guard assembly. 2. Slightly spread the opening of the coupling guard half and place it over the pump end plate. The annular groove in the guard is located around the end plate. Position the opening (flange) so that it does not interfere with the piping but still allows for access when you install the bolts. 1. Annular groove 2. Deflector fan guard 3. Coupling guard half 3.
Commissioning, Startup, Operation, and Shutdown 1. Driver 2. Coupling guard half 6. Slightly spread the opening of the remaining coupling guard half and place it over the installed coupling guard half so that the annular groove in the remaining coupling guard half faces the driver. 1. Annular groove 2. Coupling guard half 3. Driver 40 Model 3700, API Type OH2 / ISO 13709 1st and 2nd Ed. / API 610 8/9/10/11th Ed.
Commissioning, Startup, Operation, and Shutdown 7. Place the end plate over the driver shaft and locate the end plate in the annular groove at the rear of the coupling guard half. 1. Annular groove 2. End plate 8. Repeat steps 3 through 5 for the rear end of the coupling guard half, except that you hand tighten the nut. 9. Slide the rear coupling guard half towards the motor so that it completely covers the shafts and coupling. 1. Driver 2. Slide to fit 10.
Commissioning, Startup, Operation, and Shutdown a) Remove the spacer portion of the coupling. Refer to the coupling manufacturer's instructions. b) If the coupling hub diameter is larger than the diameter of the opening in the deflectorfan guard support, then remove the coupling hub. c) Loosen the thrust deflector-fan set screw.
Commissioning, Startup, Operation, and Shutdown j) Slide the thrust deflector-fan guard over the guard support and align the holes in the guard with the tapped holes in the guard support. 2. Install the thrust deflector-fan guard and support screws and tighten to the torque values shown in the Maximum torque values for 3700 fasteners table. 3. Replace the coupling hub (if removed) and spacer portion of the coupling. Refer to the coupling manufacturer's instructions for assistance.
Commissioning, Startup, Operation, and Shutdown Locate the opening (flange) so that it does not interfere with the piping but does allow access for installing the bolts. 1. Annular groove 2. Deflector fan guard 3. Coupling guard half 5. Place one washer over the bolt and insert the bolt through the round hole at the front end of the guard half. 6. Place a second washer over the exposed end of the bolt and tighten it firmly. 7. Thread a nut onto the exposed end of the bolt and tighten it firmly.
Commissioning, Startup, Operation, and Shutdown 8. Slightly spread the opening of the remaining coupling guard half and place it over the installed coupling guard half so that the annular groove in the remaining coupling guard half faces the driver. 1. Annular groove 2. Coupling guard half 3. Driver 9. Place the end plate over the driver shaft and locate the end plate in the annular groove at the rear of the coupling guard half. 1. Annular groove 2. End plate 10.
Commissioning, Startup, Operation, and Shutdown 11. Slide the rear coupling guard half towards the motor so that it completely covers the shaft and coupling. 1. Driver 2. Slide to fit 12. Repeat steps 5 through 7 for the center slots in the coupling guards. 13. Firmly tighten all of the nuts on the guard assembly. Bearing lubrication Precautions WARNING: Make sure to properly lubricate the bearings. Failure to do so can result in excess heat generation, sparks, and premature failure.
Commissioning, Startup, Operation, and Shutdown All frames in this table use a Watchdog Oiler, which has a capacity of 4 oz. (118 ml). Frame Frame oil volume ounces milliliters SA 20 600 SX 38 1115 MA 32 950 MX, LA 47 1385 LX, XLA 72 2120 XLX, XXL 89 2625 Lubricating-oil requirements Oil quality requirements Use a high-quality turbine oil with rust and oxidation inhibitors with rated viscosity shown below at 100°F (38°C).
Commissioning, Startup, Operation, and Shutdown 2. Check that the oil level is correct. The correct oil level is centered in the bullseye sight glass, when the pump is not in operation. During operation, bullseye sight gives a false oil level reading. Shown is general schematic. Oil level is below outer race of bearing. 1. Plug 2. Reservoir 3. Main body Lubricate the bearings with pure or purge-oil mist (optional) NOTICE: Do not expose an idle pump to freezing conditions.
Commissioning, Startup, Operation, and Shutdown Shaft sealing with a mechanical seal Precautions WARNING: The mechanical seal used in an Ex-classified environment must be properly certified. Prior to startup, make sure that all areas that could leak pumped fluid to the work environment are closed. NOTICE: • The mechanical seal must have an appropriate seal-flush system. Otherwise, excess heat generation and seal failure can occur.
Commissioning, Startup, Operation, and Shutdown 2. Open the air vents on the suction and discharge piping until the pumped fluid flows out. 3. Close the air vents. 1. Discharge isolation valve 2. Check valve 3. Suction isolation valve Prime the pump with the suction supply below the pump Use a foot valve and an outside source of liquid in order to prime the pump. The liquid can come from one of these sources: • A priming pump • A pressurized discharge line • Another outside supply 1.
Commissioning, Startup, Operation, and Shutdown 1. 2. 3. 4. 5. Discharge isolation valve Shutoff valve From outside supply Foot valve Check valve This illustration is an example of priming the pump with a foot valve using a bypass around the check valve: 1. 2. 3. 4. 5. By-pass line Shutoff valve Foot valve Check valve Discharge isolation valve Model 3700, API Type OH2 / ISO 13709 1st and 2nd Ed. / API 610 8/9/10/11th Ed.
Commissioning, Startup, Operation, and Shutdown Other methods of priming the pump You can also use these methods in order to prime the pump: • Prime by ejector • Prime by automatic priming pump Start the pump WARNING:Immediately observe the pressure gauges. If discharge pressure is not quickly attained, stop the driver immediately, reprime, and attempt to restart the pump. CAUTION: • Immediately observe the pressure gauges.
Commissioning, Startup, Operation, and Shutdown Pump operation precautions General considerations CAUTION: • Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the suction side since this can result in decreased performance, unexpected heat generation, and equipment damage. • Do not operate pump past the maximum flow. For maximum flow refer to the pump performance curve. • Do not overload the driver.
Commissioning, Startup, Operation, and Shutdown CAUTION: • Avoid excessive vibration levels. Excessive vibration levels can damage the bearings, stuffing box or seal chamber, and the mechanical seal, which can result in decreased performance. • Avoid increased radial load. Failure to do so can cause stress on the shaft and bearings. • Avoid heat build-up. Failure to do so can cause rotating parts to score or seize. • Avoid cavitation. Failure to do so can cause damage to the internal surfaces of the pump.
Commissioning, Startup, Operation, and Shutdown • Hardwood block or soft-faced hammer Also make sure that the final alignment is complete. Dowel the pump casing to the baseplate pedestals in order to make sure that you maintain the proper pump position. 1. Drill two holes, one in each casing mounting pad, at the locations provided. Drill the holes through both the casing mounting pads and the baseplate pedestal, when possible.
Maintenance Maintenance Maintenance schedule Maintenance inspections A maintenance schedule includes these types of inspections: • Routine maintenance • Routine inspections • Three-month inspections • Annual inspections Shorten the inspection intervals appropriately if the pumped fluid is abrasive or corrosive or if the environment is classified as potentially explosive. Routine maintenance Perform these tasks whenever you perform routine maintenance: • Lubricate the bearings. • Inspect the seal.
Maintenance 2. Inspect it. 3. Replace worn parts. Bearing maintenance These bearing lubrication sections list different temperatures of the pumped fluid. If the pump is ATEX-certified and the temperature of the pumped fluid exceeds the permitted temperature values, then consult your ITT representative. Bearing lubrication schedule Type of bearing Oil-lubricated bearings First lubrication Add oil before you install and start the pump. Change the oil after 200 hours for new bearings.
Maintenance Disassembly Disassembly precautions WARNING: • This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal unless explicitly stated in this manual. • Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks.
Maintenance Drain the pump CAUTION: • Allow all system and pump components to cool before you handle them to prevent physical injury. • If your pump is a Model NM3171, NM3196, 3198, 3298, V3298, SP3298, 4150, 4550, or 3107 there is a possible risk of static electric discharge from plastic parts that are not properly grounded. If the pumped fluid is non-conductive, drain and flush the pump with a conductive fluid under conditions that will not allow for a spark to be released to the atmosphere. 1.
Maintenance You can use penetrating oil if the adapter to the casing joint is corroded. 184 418 Seal chamber cover Jackscrew 3. Remove the back pull-out assembly using a lifting sling through the bearing frame. 4. Remove and discard the casing gasket. You will insert a new casing gasket during reassembly. 5. Remove the jackscrews. 6. Clean all gasket surfaces. Clean surfaces prevent the casing gasket from partially adhering to the casing due to binders and adhesives in the gasket material. 7.
Maintenance The impeller nut has left-hand threads. 122 198A 304 Shaft Set screw Impeller nut 3. Pull the impeller from the shaft. Use a spanning-type puller if required. 4. Remove the impeller key. Save the key for reassembly unless it is damaged. Remove the impeller (3703) CAUTION: Wear heavy work gloves when you handle impellers. The sharp edges can cause physical injury. 1. Loosen the set screw at the end of the impeller nut. 2. Loosen and remove the impeller nut.
Maintenance 3. Pull the impeller from the shaft. Use a spanning-type puller if required. 4. Remove the impeller key. Save the key for reassembly unless it is damaged. 5. Remove the impeller spacer. Save the spacer for reassembly unless it is damaged. Remove the impeller (3700LF) CAUTION: Wear heavy work gloves when you handle impellers. The sharp edges can cause physical injury. 1. Loosen and remove the impeller capscrew. The impeller capscrew has left-hand threads. 2. Pull the impeller from the shaft.
Maintenance 2. Slide the cartridge mechanical seal away from the seal-chamber cover. 3. 4. 5. 6. Install the eyebolt in the tapped hole provided in the seal-chamber cover. Rig the lifting sling to the eyebolt and the overhead lifting device. Loosen and remove the seal-chamber cover and the bearing frame bolts. Separate the seal-chamber cover from the bearing frame by tapping on the cover flange with a hardwood block or a soft-face hammer.
Maintenance 9. Remove and discard the mechanical seal O-ring or gland gasket. You will replace this with a new O-ring or gasket during reassembly. Remove the optional water-jacket cover CAUTION: • The seal-chamber cover must be adequately supported so that it cannot fall. • You must vent all air from the water jacket. If all of the air is not vented, it can cause the water jacket cover to be propelled from its fit in the seal-chamber cover. • Do not exceed 7.
Maintenance e) Remove the thrust-fan guard support. 122 123B 123E 222 228 234 234D 496Q Shaft Radial deflector fan Thrust deflector fan Deflector set screw Bearing frame Thrust deflector-fan guard Thrust deflector-fan guard support Support screws 2. Loosen and remove the thrust-bearing end cover and bearing-frame screws. 3. Pry the thrust-bearing end cover thrust deflector out of the bearing frame. Model 3700, API Type OH2 / ISO 13709 1st and 2nd Ed. / API 610 8/9/10/11th Ed.
Maintenance SA and MA thrust-bearing end covers are sealed to the bearing frame with a gasket. 109A 122 123A 228 358E 360A 370N 390C 469P Thrust-bearing end cover Shaft Thrust deflector Bearing frame Oil ring inspection plug Gasket Bearing-frame screw Thrust-bearing end-cover shim Oil ring retainer 4. Remove and discard the thrust-bearing end-cover shims. For all except SA and MA bearing frames, replace with new shims during reassembly. 5.
Maintenance 6. If your power end has the optional water-cooling package, then remove the finned-tube cooling assembly from the bearing frame. 7. Carefully withdraw the shaft and bearing assembly from the bearing frame. Take care not to damage the oil rings. If the oil rings bind or hang up, you can access them through the inspection holes and reposition them using a hooked tool made from wire. SX, MX, LA, LX, XLA, and XLX pumps have two oil rings. SA and MA pumps have one oil ring.
Maintenance If your pump is... SX, MX, LA, LX, XLA, or XLX Then... 1. Loosen and remove the radial-bearing end cover and bearingframe screws. 2. Remove and discard the radial-bearing end-cover gasket. You will replace this with a new gasket during reassembly. 3. Press the radial and thrust deflector out of the radial and thrust end covers. If you have an optional radial heat flinger, it replaces the standard radial deflector and is removed in the same manner except you loosen three set screws.
Maintenance Preassembly inspections Replacement guidelines Casing check and replacement WARNING: Avoid death or serious injury. Leaking fluid can cause fire and/or burns. Inspect and assure gasket sealing surfaces are not damaged and repair or replace as necessary. Inspect the casing for cracks and excessive wear or pitting. Thoroughly clean gasket surfaces and alignment fits in order to remove rust and debris.
Maintenance Impeller areas to inspect 101 202 and 203 Impeller Impeller wear rings Figure 11: Areas to inspect for wear on impeller Oil ring replacement Oil rings must be as round as possible in order to function properly. Replace oil rings if they are worn, distorted, or damaged beyond reasonable repair. Cartridge mechanical seal replacement Cartridge-type mechanical seals should be serviced by the seal manufacturer. Refer to the instructions from the mechanical seal manufacturer for assistance.
Maintenance • Impeller lockwasher (199A) • Impeller nut (304) • Bearing lockwasher (382) • Impeller spacer (443A) • Water jacket cover (490)* • All nuts, bolts, and screws * If supplied. Shaft replacement guidelines Shaft measurement check Check the bearing fits of the shaft. If any are outside the tolerances shown in the Bearing fits and tolerances table, then replace the shaft. Shaft straightness check Check the shaft straightness.
Maintenance Group SX MX, LA LX, XLA XLX XXL Radial (inboard) 6212 C3 6213 C3 6215 C3 6218 C3 6220 C3 Thrust (outboard) 7312 BEGAM 7312 BEGAM 7313 BEGAM 7317 BEGAM 7318 BEGAM Wear rings inspection and replacement (Not applicable for 3703/3700LF) Wear ring types All units are equipped with casing, impeller, and seal-chamber cover wear rings. When clearances between the rings become excessive, hydraulic performance decreases substantially.
Maintenance 101 202 203 Impeller Impeller wear ring Impeller wear ring (No Requirement for 3700LF) Figure 13: Impeller wear ring 125 184 230 Seal-chamber throat bushing Seal-chamber cover Seal-chamber cover wear ring Figure 14: Seal chamber cover wear ring When to replace wear rings Replace wear rings when the diametrical clearance exceeds two times the minimum clearance as shown in this table or when the hydraulic performance has decreased to unacceptable levels.
Maintenance Diameter of impeller wear ring 3.000 to 3.499 80 to 89.99 3.500 to 3.999 90 to 99.99 4.000 to 4.499 100 to 114.99 4.500 to 4.999 115 to 124.99 5.000 to 5.999 125 to 149.99 6.000 to 6.999 150 to 174.99 7.000 to 7.999 175 to 199.99 8.000 to 8.999 200 to 224.99 9.000 to 9.999 225 to 249.99 10.000 to 10.999 250 to 274.99 10.000 to 11.999 275 to 299.99 12.000 to 12.999 300 to 324.99 Minimum diametrical clearance 0.013 0.33 0.014 0.35 0.015 0.38 0.016 0.40 0.017 0.43 0.018 0.45 0.019 0.48 0.020 0.
Maintenance 3. Heat the new impeller wear rings to 180° to 200°F (82° to 93°C) using a uniform method for heating, such as an oven, and place them on the impeller wear-ring seats. 101 202 203 320 Impeller Impeller wear ring Impeller wear ring Set screw 4. Chill the new casing wear ring using dry ice or another suitable chilling substance and install the ring into the casing fit. Be prepared to tap the ring in place with a wood block or soft-faced hammer.
Maintenance c) Install the set screws and upset threads. 184 222E 230 Cover Set screw Seal-chamber-cover wear ring 6. Check the casing wear ring runout and distortion: a) Measure the bore at each set screw location with inside micrometers or vernier calipers. b) Correct any distortion in excess of 0.003 in. (0.08 mm) by machining before you trim the new impeller wear rings. 100 164 Casing Casing wear ring 7.
Maintenance NOTICE: • All replacement impeller wear rings, except those that are hard-faced, are supplied 0.020 in. to 0.030 in. (0.51 mm to 0.75 mm) oversize. • Do not machine all wear rings. Spare hard-faced impeller wear rings are supplied to pre-established clearances when both impeller and casing wear rings are renewed. 10.
Maintenance 1. Check for distortion at the set screw areas. 2. Check the shaft runout and all mating surfaces of the shaft and impeller hub for perpendicularity. 3. True up all damaged surfaces. 4. Recheck the impeller wear-ring runout.
Maintenance b) Press the bushing out of the fit towards the bearing-frame side of the seal-chamber cover bore. 125 184 Bushing Seal-chamber cover 2. Install the new seal-chamber cover bushing: a) Thoroughly clean the bushing fit in the seal-chamber cover. b) Chill the new bushing using dry ice or another suitable chilling substance, and install the bushing into the cover fit. Tap the bushing in place with a wood block or soft-faced hammer.
Maintenance Bearing-frame inspection Checklist Check the bearing frame for these conditions: • Visually inspect the bearing frame and frame foot for cracks. • Check the inside surfaces of the frame for rust, scale, or debris. Remove all loose and foreign material. • Make sure that all lubrication passages are clear. • Inspect the inboard-bearing bores. If any bores are outside the measurements in the Bearing fits and tolerances table, replace the bearing frame.
Maintenance Location Thrust (Outboard) Description SA Shaft OD 1.9691 (50.013) 1.9686 (50.002) Interference 0.0001 (0.002) 0.0010 (0.025) Bearing ID 1.9680 (49.998) 1.9685 (50.000) Frame ID 4.3307 (110.0000 4.3315 (110.022) Clearance 0.0000 (0.000) 0.0015 (0.037) Bearing OD 4.3307 (110.000) 4.3301 (109.985) SX 2.3628 (60.015) 2.3623 (60.002) 0.0001 (0.002) 0.0012 (0.030) 2.3616 (59.985) 2.3622 (60.000) 5.1181 (130.000) 5.1191 (130.025) 0.0000 (0.000) 0.0017 (0.043) 5.1181 (130.000) 5.1174 (129.982) MA 2.
Maintenance Pure oil-mist lubricated power ends are assembled in the same manner as ring oil-lubricated power ends. Oil rings are not furnished with pure oil-mist lubrication. Disregard any reference to those parts. 1. Install the radial (inboard) bearing on the shaft. 112 114 122 136 168 382 Duplex thrust bearing Oil rings Shaft Thrust-bearing locknut Radial bearing Lockwasher 2. Install the oil rings and bearings: a) Install the oil rings on the shaft.
Maintenance f) Coat the internal bearing surfaces with lubricant to be used in service. 119A 123 228 360 370P Thrust end cover Deflector Bearing frame Radial-bearing end-cover gasket Bearing-frame screws 3. Press the radial INPRO oil seal into the radial end cover. 4. Install the radial-bearing end cover and new end-cover gasket on the bearing frame. Make sure that the expulsion part is at the 6 o'clock position and is properly seated.
Maintenance 123 228 Radial INPRO oil seal Bearing frame 6. Assemble the shaft assembly and bearing frame: a) Coat the outer races of the bearings with a compatible oil. b) Coat the internal bearing surfaces of the bearing frame with a compatible oil. c) Position the oil rings in the grooves of the shaft.
Maintenance d) Carefully guide the shaft and bearing assembly into the bearing frame until the thrust bearing is seated against the shoulder of the frame. Make sure that the oil rings do not bind or become damaged. Do not force the assembly together. e) Observe the oil rings through the sight glass in the bearing frame. If the oil rings are not properly seated in the grooves in the shaft, insert a hook-shaped tool made from wire through the inspection connections.
Maintenance 3. Install and tighten the thrust-bearing end cover and bearing-frame screws evenly to the torque values in the Maximum torque values for 3700 fasteners table. 4. Determine the axial end play as follows: a) Mount the dial indicator. b) Use a lever to apply axial force to the impeller end of the shaft and firmly seat the thrust bearing against the shoulder in the bearing frame.
Maintenance If your power end... Then... Has the optional air-cooling 1. Position the thrust-fan guard support on the thrust-bearing end package cover. 2. Install and tighten the thrust-bearing end cover and bearing-frame screws evenly to torque values shown in the Maximum torque values for 3700 fasteners table. 3. Install the thrust fan over the shaft. 4. Position the thrust-deflector fan approximately 0.030 in. (0.8 mm) from the thrust INPRO seal on SA and MA pumps.
Maintenance 88 Check Shaft impeller fit Procedure 1. 2. Mount the dial indicator on the bearing frame. Rotate the shaft through a maximum arc from one side of the keyway to the other. If the total indicator reading is greater than 0.002 in. (0.050 mm), determine the cause and correct it. Shaft seal fit 1. 2. Mount the dial indicator. Rotate the shaft so that the indicator rides along the shaft surface for 360°. If the total indicator reading is greater than 0.002 in. (0.
Maintenance Check Bearing-frame face Procedure 1. 2. Mount the dial indicator on the shaft. Rotate the shaft so that the indicator rides along the bearing-frame face for 360°. If the total indicator reading is greater than 0.004 in. (0.10 mm), then disassemble and determine the cause and correct it. Bearing-frame lock 1. 2. Mount the dial indicator on the shaft. Rotate the shaft so that the indicator rides along the bearing-frame lock for 360°. If the total indicator reading is greater than 0.004 in.
Maintenance Install the optional water-jacket cover 1. Install the outer and inner water-jacket-cover O-rings into the grooves in the water jacket cover. 184 412S 490 497T Seal-chamber cover Outer water-jacket-cover O-ring Water jacket cover Outer and inner water-jacket-cover O-ring 2. Lubricate the sealing surfaces in the seal-chamber cover and O-rings with a suitable lubricant. 3. Insert the water jacket cover with O-rings into the fit in the seal-chamber cover.
Maintenance Install the seal-chamber cover 1. Install the eyebolt in the tapped hole provided in the seal-chamber cover. 122 184 228 230 370H Shaft Seal-chamber cover Bearing frame Seal-chamber cover wear-ring Bearing-frame bolts 2. Set up a sling from the eyebolt to the overhead lifting device. 3. Lift the seal-chamber cover and position it so that it aligns with the shaft. 4.
Maintenance b) Rotate the shaft so that the indicator rides along the seal-chamber cover face for 360°. If the total indicator reading is greater than 0.005 in. (0.13 mm), determine the cause and correct it. 6. Check the seal-chamber cover lock runout: a) Mount the dial indicator on the shaft. b) Rotate the shaft so that the indicator rides along the seal-chamber cover lock for 360°. If the total indicator reading is greater than 0.005 in. (0.13 mm), determine the cause and correct it.
Maintenance b) Rotate the shaft so that the indicator rides on the seal-chamber cover wear-ring surface for 360°. If the total indicator reading exceeds 0.006 in. (0.15 mm), determine the cause and correct it. 8. Check the seal-chamber face runout: a) Mount a dial indicator on the shaft. Model 3700, API Type OH2 / ISO 13709 1st and 2nd Ed. / API 610 8/9/10/11th Ed.
Maintenance b) Rotate the shaft so that the indicator rides along the seal-chamber face for 360°. If the total indicator reading is greater than the values shown in this table, determine the cause and correct it. Table 9: Maximum Allowable Seal Chamber Face Runout Group Maximum Allowable Total Indicator Reading SA 0.0018 in. (0.045 mm) SX, MA 0.002 in. (0.05 mm) MX, LA 0.0024 in. (0.06 mm) LX, XLA 0.0026 in. (0.065 mm) XLX 0.0028 in. (0.07 mm) XXL 0.0031 in. (0.08 mm) 9.
Maintenance Install the cartridge-type mechanical seal and seal-chamber cover NOTICE: Refer to the mechanical seal manufacturer’s drawings and instructions for assistance during the installation of the mechanical seal. 1. Remove the impeller. a) Loosen and remove the impeller nut. The impeller nut has left-hand threads. b) Remove the impeller, impeller key, and seal-chamber cover as described in the Disassembly section. 2.
Maintenance 6. Disengage the spacer ring or clips. 7. Verify that the shaft turns freely. If you detect rubbing or excessive drag, then determine the cause and correct it. Determining impeller spacer thickness (applicable for 3703/3700LF) Applicable only to a new spare impeller spacer With an assembled power end: 1. Attach the seal chamber cover to the bearing frame. 2. Install impeller spacer as supplied between shaft and impeller. 3. Secure impeller to shaft with impeller cap screw or nut. 4.
Maintenance 4. Install the impeller nut and tighten to the torque values shown in the Maximum torque values for 3700 fasteners table. The impeller nut has left-hand threads. 5. Tighten the set screw in the end of the impeller nut. 6. Verify that the shaft turns freely. If you notice any rubbing or excessive drag, then determine the cause and correct it. If you notice any rubbing or excessive drag, then determine the cause and correct it.
Maintenance Install the back pull-out assembly in the casing 1. Install a new casing gasket on the gasket surface of the casing. You can apply anti-galling compound to the casing fits to aid in assembly and disassembly. 2. Replace the back pull-out assembly in the casing using a lifting sling through the bearing frame or other suitable means. 3. Slide the back pull-out assembly into the proper position in the casing by loosening the jacking bolts evenly. Make sure that the casing gasket is not damaged. 4.
Maintenance Post-assembly checks Perform these checks after you assemble the pump, then continue with pump startup: • Rotate the shaft by hand in order to make sure that it rotates easily and smoothly and that there is no rubbing. • Open the isolation valves and check the pump for leaks. Assembly references Maximum torque values for fasteners About this table The torque values specified in this table are for dry threads.
Maintenance Item Part 355 370N 370P 198* 304# 136 Fastener Size Nut gland 5/8-11 UNC stud 3/4-10 UNC Screw - 1/2-13 UNC thrust 5/8-11 UNC bearing end cover to frame Screw - 5/16-18 UNC radial bearing end cover to frame Pump to 7/8-9 UNC base 1 1/4-7 UNC Impeller 3/8-16 UNC cap 3/4-10 UNC screw 7/8-9 UNC Impeller 5/8-18 UNF nut 3/4-16 UNF 1-12 UNF Locknut, 1.967-18 bearing 2.157-18 2.360-18 2.548-18 3.340-12 3.
Maintenance • • • • • • • • • • • • • • • • • • • • • • • Bearing locknut (136) Bearing lockwasher (382) Cartridge mechanical seal (383) Casing gasket (351) Casing wear ring (164) (Applicable for 3700/3710) Finned-tube cooling assembly (494) Impeller nut (304) (Applicable for 3700/3710/3703) Impeller cap screw (198) (Applicable for 3700LF) Impeller wear ring - casing side (202) (Applicable for 3700/3710) Impeller wear ring - cover side (203) (Applicable for 3700/3710) Oil rings (114) Oiler with wire guard
Troubleshooting Troubleshooting Operation troubleshooting Symptom The pump is not delivering liquid. Cause The pump is not primed. The suction line is clogged. The impeller is clogged. The shaft is rotating in the wrong direction. The foot valve or suction pipe opening is not submerged enough. The pump is not producing the rated flow or head. The suction lift is too high. The gasket or O-ring has an air leak. The stuffing box has an air leak. The impeller is partly clogged.
Troubleshooting Alignment troubleshooting Symptom Cause Horizontal (side-to-side) alignment cannot The driver feet are bolt-bound. be obtained (angular or parallel). Remedy Loosen the pump's hold-down bolts, and slide the pump and driver until you achieve horizontal alignment. The baseplate is not leveled properly and 1. is probably twisted. 2. 3. Determine which corners of the baseplate are high or low. Remove or add shims at the appropriate corners. Realign the pump and driver.
Parts Listings and Cross-Sectionals Parts Listings and Cross-Sectionals Parts list Table 12: Parts list with standard materials of construction 3700/3703/3710/3700LF The materials in this table are typical. Refer to the order documentation for the actual materials furnished.
Parts Listings and Cross-Sectionals Item Part name 408A 412 418 425 443A 469P 494 497F 497H 497S Plug, oil drain O-ring, thrust bearing end cover Bolt, jacking Nut, casing stud Impeller spacer Retainer, oil ring Finned tube cooling assembly O-ring, thrust deflector O-ring, radial deflector O-ring, radial end cover Quantity per pump 1 1 4 Varies 1 2 1 1 1 1 Construction - API designation Steel with magnetic insert Buna N 2210 2239 2229 2229 2229 2285 Stainless steel with copper fins Buna N Buna N Buna N
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Visit our website for the latest version of this document and more information: www.gouldspumps.com Goulds Pumps 240 Fall Street Seneca Falls, NY 13148 USA Tel. 1-800-446-8537 Fax (315) 568-2418 © 2013 ITT Corporation The original instruction is in English. All non-English instructions are translations of the original instruction. Form en_US.2014.03.IOM.
